Process and apparatus for making water soluble pouches

ABSTRACT

A process and apparatus for forming water soluble pouches.

FIELD OF THE INVENTION

Process and apparatus for making water soluble pouches.

BACKGROUND OF THE INVENTION

Water soluble pouches are widely used to dose substrate treatment compositions such as laundry detergent and dishwashing detergent. The typical process used to manufacture such pouches is to convert a web of material into individual pouches. To form a pouch from multiple webs of materials typically requires that seals between webs of material or materials need to be made to form a pouch that does not leak. Leaks that occur in seams can result in a product that is messy to store and use and may also result in a product that does not function as intended.

The converting process for forming water soluble pouches can include a fluid distribution manifold. The function of the manifold is to distribute a single stream of substrate treatment composition into multiple streams of substrate treatment composition. The streams of substrate treatment composition from the manifold are directed to particular locations on a web that are or will be formed into a pouch. The traditional method of constructing a fluid distribution manifold is to provide two solid blocks of material and machining out material from the solid blocks to provide for fluid pathways. The blocks are positioned in a facing relationship and have a gasket between the two blocks to prevent leakage from the fluid pathways into the space between the two blocks. The gasket has portions of material removed there from coincident with portions of the blocks that are machined. Together, the blocks and gasket define one or more channels in and through the manifold.

There are at least two problems that arise from the typical approach for constructing a manifold. First, the gasket is critical to maintaining function of the manifold. If the gasket is improperly aligned, has wrinkles or folds, or is degraded by the fluid with which the gasket comes into contact with, the manifold may leak via a flow pathway between the blocks of material. Second, flow pathways passing through the blocks are typically provided by drilling and or routing out material from the blocks. The intersections of channels routed out in surfaces of the solid blocks and holes drilled through the blocks tend to have sharp intersections and the cross section of the flow paths is irregular and non-circular in portions of the pathways. These sharp intersections of flow paths and irregularly shaped non-circular portions can result in uncontrollable initiation and termination of the flow of substrate treatment composition, air entrapment, and or stagnant liquid in the flow pathways.

Leaks in the manifold and uncontrollable initiation and termination of flow of the substrate treatment composition from the manifold can result in some of the substrate treatment composition ending up on the portion of the web where a seam is to be located. The presence of the substrate treatment composition in the seam area can impede the ability to make a competent seal between the webs of material used to form the pouch. This can result in the final formed pouch having a leak at the time of manufacture or a weak seal that ultimately develops into a leak after manufacture and before use by the consumer.

With these limitations in mind, there is a continuing unaddressed need for processes for manufacturing water soluble pouches that can form water soluble pouches that do not have a leak at the time of manufacture or develop a leak after manufacture and before use by the consumer.

SUMMARY OF THE INVENTION

A process for forming a plurality of water soluble pouches (50) comprising the steps of: providing a water soluble first web (30); feeding the first web onto a forming surface (140) comprising a plurality of pockets (70); thermoforming the first web to conform the first web to the pockets to form chambers (55), each of the chambers surrounded by a land area (37) of the first web; providing an assembled manifold (100), wherein the assembled manifold comprises: a frame (10); and a plurality of integrally formed fluid distributors (60) joined to the frame; wherein each of the integrally formed fluid distributors comprises a primary flow path (80); and wherein the primary flow path is in fluid communication with a plurality of secondary flow paths (90); dispensing substrate treatment composition from the secondary flow paths into the compartments; providing a water soluble second web (40); and sealing the water soluble second web to the land areas of the water soluble first web to form the plurality of water soluble pouches.

An assembled manifold comprising: a frame (10); and a plurality of integrally formed fluid distributors (60) joined to the frame; wherein each of the integrally formed fluid distributors comprises a primary flow path (80); and where the primary flow path is in fluid communication with a plurality of secondary flow paths (90).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an apparatus for forming soluble unit dose substrate treatment composition pouches.

FIG. 2 is an assembled manifold comprising a frame and a plurality of integrally formed fluid distributors that comprise a plurality of flow paths.

FIG. 3 is a cross section view of a portion of an integrally formed fluid distributor.

FIG. 4 is a photograph of initiation of fluid flow from a nozzle connected to a manifold formed from two blocks of material.

FIG. 5 is a photograph of initiation of fluid flow from a nozzle connected to a manifold formed from two blocks of material, the flow rate of liquid being higher in FIG. 5 than FIG. 6.

FIG. 6 is a photograph of initiation of fluid flow from a nozzle connected to an assembled manifold, the flow rate of fluid being approximately the same as that shown in FIG. 5.

FIG. 7 is a top plan view of a first web deformed into a plurality of chambers and the position of the secondary flow paths in relationship to the chambers.

DETAILED DESCRIPTION OF THE INVENTION

An apparatus 1 for forming soluble unit dose substrate treatment composition pouches 50 is shown in FIG. 1. The substrate treatment composition can be, by way of non-limiting example, a laundry treatment agent, a dishware treatment agent, a hard surface treatment agent, or similar. A water soluble first web 30 is provided and fed onto a forming surface 140. The water soluble first web 30 can be carried by the forming surface 140 beneath a frame 10 that carries a plurality of integrally formed fluid distributors 60. The forming surface 140 can be a drum like that shown in FIG. 1. The forming surface 140 can rotate at a fixed angular velocity. The forming surface 140 can have a plurality of pockets 70 into which the water soluble first web 30 can be drawn by vacuum applied to the pockets 70. By drawing the first web 30 into the pockets 70 a plurality of chambers 55 (see FIG. 4) can be formed. The chambers 55 can be surrounded by a land area 37 (see FIGS. 4 and 5). The water soluble first web 30 can be conveyed in a machine direction MD. The forming surface 140 can have a plurality of lanes of pockets 70 in a direction orthogonal to the machine direction MD. The forming surface 140 can be a flat continuous conveyor that runs in an endless loop, by way of non-limiting example a belt system.

Once portions of the water soluble first web 30 are drawn into the pockets 70, the first web 30 can be carried beneath the frame 10 and liquid substrate treatment composition can be dispensed from the integrally formed fluid distributors 60 into the portions of the first web 30 drawn into the pockets 70. The liquid substrate treatment composition can be provided to the integrally formed distributors 60 by a feed line 20. Liquid substrate treatment composition is dispensed periodically from the fluid distributors 60. This is so that liquid substrate treatment composition is dispensed only into the portions of the first web 30 drawn into pockets 70 and the land areas between the deformed portions of the water soluble first web 30 are free from liquid substrate treatment composition. Once the fluid is dispensed from the fluid distributors 60, a water soluble second web 40 can be provided. The water soluble second web 40 can be conveyed to be on top of the water soluble first web 30 and the water soluble first web 30 and second web 40 are sealed to one another to form pouches 50. The water soluble second web 40 can be sealed to the land areas 37 of the water soluble first web 30 to form a plurality of water soluble pouches 50. Downstream of the forming surface 140 the pouches 50 can be separated from one another by cutting.

The water soluble first web 30 and water soluble second web 40 can comprise a polymer selected from the group consisting of polyvinyl alcohols, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatine, natural gums such as xanthum and carragum. Suitable polymers are selected from polyacrylates and water-soluble acrylate copolymers, methylcellulose, carboxymethylcellulose sodium, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylates, and suitably selected from polyvinyl alcohols, polyvinyl alcohol copolymers and hydroxypropyl methyl cellulose (HPMC), and combinations thereof. The level of polymer in the water soluble first web 30 and water soluble second web 40, for example a PVA polymer, can be at least 60%. The polymer can have any weight average molecular weight, such as from about 1000 to about 1,000,000, or even from about 10,000 to about 300,000, or even from about 20,000 to about 150,000.

Suitable water soluble first web 30 and water soluble second web 40 can be webs supplied by Monosol under the trade references M8630, M8900, M8779, M8310, films described in U.S. Pat. No. 6,166,117 and U.S. Pat. No. 6,787,512 and PVA films of corresponding solubility and deformability characteristics. Further suitable sheets can be those described in US2006/0213801, WO 2010/119022 and U.S. Pat. No. 6,787,512.

Together the frame 10 and the plurality of integrally formed fluid distributors 60 form an assembled manifold, as shown in FIG. 2, for example. As shown in FIG. 2, the frame 10 and integrally formed distributors 60 can have a machine direction MD and a cross direction CD orthogonal to the machine direction MD. The frame 10 can house the integrally formed fluid distributors 60. The frame 10 can be a predominantly solid block of material having sockets, spaces, or other shape to accommodate the integrally formed fluid distributors 60 being attached to the frame 10. The frame 10 can be an open frame 10 having a minimal amount of material so as to be able to maintain integrity of the frame 10 during operation of the apparatus 1.

During operation of the apparatus 1, the frame 10 may reciprocate in space so as to track the pockets 70 as they move beneath the frame 10. Advantageously, the frame 10 can be an open frame 10 so as to minimize the amount of inertia that must be overcome by the motor providing for acceleration and deceleration of the frame 10. In operation, the forming surface 140 may be continuously moving to move the first web 30 in the machine direction. As a pocket 70 approaches the integrally formed distributors 60, the frame 10 can be positioned so that a secondary flow path 90 is over the pocket 70 to be filled. As the forming surface 140 continues to drive the first web 30 in the machine direction MD, the frame 10 moves in concert with the pocket 70 and liquid is dispensed from the secondary flow path 90 to the portion of the first web 30 that is deformed into the pocket 70 to form part of the pouch 50. The liquid flow from the secondary flow path 90 is stopped before the forming surface 140 moves beyond the range of movement of the secondary flow path 90. Once liquid flow is stopped, the frame reciprocates to be in position over another portion of the first web 30 that is formed into a portion of a pouch 50 in a pocket 70 of the forming surface 140.

The integrally formed fluid distributors 60 can be joined to the frame 10. The integrally formed fluid distributors 60 and the frame 10 can be integrally formed with one another to provide for fluid distributors 60 being joined to the frame 10. The integrally formed fluid distributors 60 can be joined to the frame 10 by bolts, welding, adhesive, tape, glue, screws, rivets, press fit, and any other methods for joining or associating two adjacent articles.

The fluid distributors 60 operate to distribute liquid substrate treatment composition to multiple pouches 70 and or multiple chambers of one or more pouches 70. As shown in FIGS. 2 and 3, each of the fluid distributors 60 can comprise a primary flow path 80. Optionally, each of the fluid distributors 60 can comprise a plurality of primary flow paths 80. The primary flow path 80 can be in fluid communication with a plurality of secondary flow paths 90. If there are a plurality of primary flow paths 80, each primary flow path 80 can be in fluid communication with a plurality of secondary flow paths 90.

As shown in FIG. 2, the secondary flow paths 90 can be curved or smoothly shaped. Such curved secondary flow paths 90 can be devoid of inactive corners within the secondary flow paths 90. In traditional manifold construction in which two blocks of material are machined to provide for fluid distribution within and from the manifold, the channels and drilled holes to providing the flow paths can have sharp corners and or intersections having sharp edges. The sharp corners and intersections of the flow paths can result in inactive portions of the fluid pathways. Inactive portions can give rise to accumulation of gasses, agglomerations of components of the fluid being distributed and conducted, and irregular fluid flow.

Inactive corners within the secondary flow paths 90 can results in irregular initiation of fluid dispensing from the secondary flow paths 90. The irregular initiation of fluid dispensing may occur because the gasses and or agglomerations accumulated in the inactive portions may deform or compress when pressure is applied the fluid being conducted. Further the accumulated gasses and or agglomerations may move uncontrollably within the second flow path 90 giving rise to irregular initiation of fluid dispensing.

As shown in FIG. 2, the frame 10 has a machine direction MD and a cross direction CD orthogonal to the machine direction MD. Each of the integrally formed fluid distributors 60 can comprise a primary flow path 80. Each of the integrally formed fluid distributors 60 can comprise a plurality of primary flow paths 80. Each of the integrally formed fluid distributors 60 can comprise a plurality primary flow paths 80 aligned with one another in the machine direction MD. Each of the integrally formed fluid distributors 60 can comprise a plurality of primary flow paths 80 aligned with one another in the machine direction MD. This can be practical if more than one pouch 70 in the machine direction MD or chamber of a pouch in the machine direction MD is being filled simultaneously for some portion of time. To provide for the ability to individually active fluid dispensing from separate secondary flow paths 90 located at different positions in the machine direction MD, each of the primary flow paths 80 aligned with one another in the machine direction MD can be in fluid communication with a separate secondary flow path 90.

The integrally formed fluid distributors 60 can comprise a plurality of primary flow paths 80 aligned with one another in the cross direction CD. Each of the primary flow paths 80 can be in fluid communication with separate fluid distributors 60.

As shown in FIG. 2, the assembled manifold 100 can comprise a plurality of primary flow paths 80 aligned with one another in the cross direction CD. The assembled manifold 100 can comprises a plurality of primary flow paths 80 and or secondary flow paths 90 aligned with one another in the cross direction CD.

The primary flow paths 80 and secondary flow paths 90 can be formed of a material selected from the group consisting of titanium 6-4, cobalt-chrome, and stainless steel. Any material that can be used in a process known as 3-D printing or additive manufacturing that is compatible with the liquid being transported through the fluid distributors 60 can be used. The integrally formed fluid distributors 60 can be formed by additive manufacturing, which is colloquially referred to as three-dimensional printing. So the integrally formed fluid distributors 60 can be referred to as three-dimensionally printed fluid distributors 60. In an additive manufacturing process, the fluid distributers 60 are formed by building up layers of material constituting the fluid distributors 60. The constituent material of the integrally formed fluid distributors 60 can be any material that can be used in an additive manufacturing process, has appropriate mechanical properties to be employed as an integrally formed fluid distributor 60, and is compatible with the liquid to be dispensed from the integrally formed fluid distributors 60. So the integrally formed distributors 60 can be referred to as additive manufactured integrally formed distributors 60. The integrally formed distributors 60 can also be referred to as three-dimensionally printed integrally formed distributors 60. The frame 10 and the fluid distributors 60 can be integrally formed with one another.

Each of the secondary flow paths 90 can terminate in a separate nozzle 110, as shown in FIG. 3. The nozzle 110 can constrict flow of the liquid to provide for a steady stream of fluid during fluid dispensing though the secondary flow path 90 and nozzle 110. As shown in FIG. 3, the first web 30 can be drawn into the pocket 70 on the forming surface 140. Each pocket 70 can be connected to a vacuum tube 120 that can help draw the first web 30 into conformance with the pocket 70. The first web 30 can optionally be heated to permit the first web 30 be more easily thermoformed into the pocket 70. The first web 30 can be thermoformed to conform with the pocket 70.

The primary flow paths 80 can have inside diameter of from about 1 mm to about 8 mm. The secondary flow paths 90 can have an inside diameter of from about 1 mm to about 6 mm. The wall thickness of the primary flow paths 80 and secondary flow paths 90 can be from about 0.2 mm to about 3 mm. The spacing between second flow paths 90 that are connected to a single primary flow path 80 can be from about 25 to about 60 mm. The length of each secondary flow path 90 can be from about 10 mm to about 60 mm. The spacing between primary flow paths 80 located in line with one another in the cross direction can be from about 25 to about 120 mm. The spacing between secondary flow paths 90 located in line with one another in the machine direction MD can be from about 25 to about 60 mm. For each nearest neighbors primary flow paths 80, the primary flow paths 80 can be from about 8 mm to about 40 mm in the machine direction MD and from about 8 mm to about 40 mm in the cross direction MD.

FIGS. 4 and 5 illustrate the start of dispensing from nozzles 110 of a manifold formed from two blocks of machined material that are assembled together with a gasket between the two blocks of material. The liquid being dispensed can be a substrate treatment composition, such as by non-limiting example, selected from the group consisting of a laundry treatment composition, a dish treatment composition, a hard surface treatment composition. The liquid being dispensed in FIGS. 4 and 5 is a liquid laundry detergent of the type marketed by Procter & Gamble Company. As shown in FIGS. 4 and 5, at the onset of dispensing from the nozzles 110 of a common manifold is sporadic with irregular droplet size and splattering. FIG. 6 illustrates dispensing from nozzles 110 of an assembled manifold 100 as described herein. As shown in FIG. 6, the onset of dispensing from the nozzles 110 is coherent with no irregular droplets being formed and no splattering. The difference in the behavior of the onset of dispensing between the two different manifold designs is believed to arise as a result of the secondary flow paths 90 of the assembled manifold 100 are devoid of inactive corners within the secondary flow paths 90, unlike the flow paths in the manifold built by traditional methods.

The behavior of flow observable in FIGS. 4 and 5 can adversely affect the quality of the pouches 50 manufactured using such a manifold. The drips shown in FIGS. 4 and 5 can end up landing on the land areas 37 between chambers 55. Typically, those areas of the pouch 50 are where the water soluble first web 30 and water soluble second web 40 are seamed to one another. The presence of the substrate treatment composition in the seam area can impede the ability to make a competent seal between the webs of material used to form the pouch. This can result in the final formed pouch having a leak at the time of manufacture or a weak seal that ultimately develops into a leak after manufacture and before use by the consumer. Dispensing from a integrally formed fluid distributor 60 as described herein is shown in FIG. 6. Since initiation of flow from the secondary flow paths 90 is regular, the delivery of the substrate treatment composition to the chambers 55 is predictable and the operating speed of the various components of the apparatus 1 can set so that no or some minimal acceptable amount substrate treatment composition is delivered to the land areas 37. This can permit a high quality seam between the water soluble first web 30 and water soluble second web 40.

A portion of a water soluble pouch 50 can be filled by the following process. First, an assembled manifold 100, as described herein, can be provided. Then liquid substrate treatment composition can be dispensed from the assembled manifold into a portion of the water soluble pouch 50. The portion of the water soluble pouch 50 that is formed can be the first web 30. After such portion is filled, a second web 40 can be sealed to the first web 30 to form one or more pouches 50.

The configuration of the secondary flow paths 90 shown in FIG. 2 can be practical for pouches 50 that are dual compartment pouches. For example, the first web 30 can be formed into the precursor for pouches 50 as shown in FIG. 8. The chambers 55 can be shaped to that the centroid of each chamber 55 is offset from the centroid of the other chamber 55. Having the centroids offset from one another can make it more practical to fill both chambers 55 of a single pouch 50 simultaneously for at least some portion of the dispensing cycle of each secondary flow path 90.

A grouping of the precursor for what ultimately can become four water soluble pouches 50 is shown in FIG. 7. Each of the similarly shaped and oriented chambers 55 are aligned with one another in the machine direction MD and the cross direction CD. This can provide the ability to fill multiple chambers 55 aligned with one another in the machine direction on the forming surface 140 at the same time. This can also provide the ability to fill multiple chambers 55 across the forming surface 140 in the cross direction CD.

In FIG. 7, the secondary flow paths 90 designated as A can dispense liquid simultaneously. With the secondary flow paths 90 arranged as such, each of the primary flow paths 80 can be aligned with other primary flow paths 80 in the cross direction CD and with other primary flow paths 80 in the machine direction MD. The secondary flow paths 90 aligned with one another in the cross direction CD can dispense liquid simultaneously to the portions of the first web 30 deformed in to pockets 70.

The secondary flow paths 90 designated B can dispense liquid simultaneously in the same manner. The secondary flow paths 90 designated A can start dispensing liquid before the secondary flow paths 90 designated B. The secondary flow paths 90 designated A can cease dispensing liquid before the secondary flow paths 90 designated B cease to dispense liquid.

Similarly, secondary flow paths 90 designated A can commence dispensing liquid before the secondary flow paths 90 designated C start to dispense liquid. The secondary flow paths 90 designated A can cease dispensing liquid before the secondary flow paths 90 designated C cease to dispense liquid. The secondary flow paths 90 designated B and D can be operated in the same manner as the secondary flow paths 90 designated A and C are operated.

The integrally formed fluid distributors 60 can distribute two or more substrate treatment compositions that differ from one another. Such an arrangement can be practical for forming a single pouch 50 that has two separate chambers 55 each of which contain a different substrate treatment composition. For instance, as shown in FIG. 7, the chambers 55 associated with secondary flow paths 90 designated as A can provide one type of substrate treatment composition and the chambers 55 associated with secondary flow paths 90 designated as B can provide another type of substrate treatment composition.

The substrate treatment composition dispensed from secondary flow paths 90 designated as C can be the same as the substrate treatment composition dispensed from secondary flow paths 90 designated as A. Similarly, the substrate treatment composition dispensed from secondary flow paths 90 designated as D can be the same as the substrate treatment composition dispensed from secondary flow paths 90 designated as B. The substrate treatment composition dispensed from secondary flow paths 90 designated as A and C can differ from the substrate treatment composition dispensed from secondary flow paths 90 designated as B and D.

The substrate treatment composition can be any of the substrate treatment agents presently marketed as TIDE PODS, CASCADE ACTION PACS, CASCADE PLATINUM, CASCADE COMPLETE, ARIEL 3 IN 1 PODS, TIDE BOOST ORIGINAL DUO PACs, TIDE BOOST FEBREZE SPORT DUO PACS, TIDE BOOST FEE DUO PACS, TIDE BOOST VIVID WHITE BRIGHT PACS, DASH, FAIRY (PLATINUM, ALL-IN ONE), YES (PLATINUM ALL-IN ONE), JAR (PLATINUM, ALL-IN ONE, and DREFT (PLATINUM, ALL-IN ONE) by The Procter & Gamble Company in various geographies globally.

The pouch 50 can be sized and dimensioned to fit in an adult human hand. The pouch 50 can have a volume less than about 70 mL. The pouch 50 can have a volume less than about 50 mL. The pouch 50 can have a volume less than about 40 mL. The edges of the pouch 50 can have a length of from about 10 mm to about 70 mm. The edges of the pouch 50 can have a length of from about 20 mm to about 60 mm. The edges of the pouch 50 can have a length of from about 25 mm to about 50 mm.

The edges of the pouch 50 can each have a length less than about 100 mm, or even less than about 60 mm, or even less than about 50 mm. The plan view of the of the water soluble pouch 50 can be substantially rectangular, substantially square, substantially circular, elliptical, superelliptical, or any other desired shape that is practical to manufacture. The overall plan area of the water soluble pouch can be less than about 10000 mm², or even less than about 2500 mm². Sized and dimensioned as such, the water soluble pouch 50 can fit conveniently within the grasp of an adult human hand. Further, for water soluble pouches 50 intended for use in automatic dishwashing machines, such a size can conveniently fit in the detergent receptacle within the machine.

The substrate treatment composition can be selected from the group consisting of liquid laundry detergent, a liquid dishwashing detergent, a liquid bleaching agent, a powdered bleaching agent, a liquid fabric softener, a liquid laundry scent additive, a liquid fabric care benefit agent, and combinations thereof. The substrate treatment composition can be a fabric softener comprising a quaternary ammonium salt and or a dehydrogenated tallow dimethyl ammonium chloride and or a diethyl ester dimethyl ammonium chloride. A substrate treatment composition can be formulated to treat a substrate selected from the group consisting of glassware, dishware, flooring, textiles, tires, automobile bodies, teeth, dentures, skin, fingernails, toenails, hair, appliance surfaces, appliance interiors, toilets, bathtubs, showers, minors, deck materials, windows, and the like.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

1-15. (canceled)
 16. A process for forming a plurality of water soluble pouches comprising the steps of: providing a water soluble first web; feeding said first web onto a forming surface comprising a plurality of pockets; thermoforming said first web to conform said first web to said pockets to form chambers, each of said chambers surrounded by a land area of said first web; providing an assembled manifold, wherein said assembled manifold comprises: a frame; and a plurality of integrally formed fluid distributors joined to said frame; wherein each of said integrally formed fluid distributors comprises a primary flow path; and wherein said primary flow path is in fluid communication with a plurality of secondary flow paths; dispensing substrate treatment composition from said secondary flow paths into said chambers; providing a water soluble second web; and sealing said water soluble second web to said land areas of said water soluble first web to form said plurality of water soluble pouches.
 17. The process for forming a plurality of water soluble pouches according to claim 16, wherein each of said secondary flow paths is devoid of inactive corners within said secondary flow paths.
 18. The process for forming a plurality of water soluble pouches according to claim 17, wherein said frame has a machine direction and cross direction orthogonal to said machine direction, wherein each of said fluid distributors comprises a plurality of said primary flow paths aligned with one another in said machine direction.
 19. The process for forming a plurality of water soluble pouches according to claim 18, wherein each of said primary flow paths aligned with one another in said machine direction are in fluid communication with a separate secondary flow path.
 20. The process for forming a plurality of water soluble pouches according to claim 18, wherein each of said fluid distributors comprises a plurality of said primary flow paths aligned with one another in said cross direction, wherein each of said primary flow paths are in fluid communication with separate fluid distributors.
 21. The process for forming a plurality of water soluble pouches according to claim 20, wherein said integrally formed fluid distributor distributes two or more said substrate treatment compositions that differ from one another.
 22. The process for forming a plurality of water soluble pouches according to claim 18, wherein said assembled manifold comprises a plurality of said primary flow paths aligned with one another in said cross direction.
 23. The process for forming a plurality of water soluble pouches according to claim 18, wherein each of said secondary flow paths terminates at a separate nozzle.
 24. The process for forming a plurality of water soluble pouches according to claim 16, wherein said primary flow paths and secondary flow paths comprise a material selected from the group consisting of titanium 6-4, cobalt-chrome, and stainless steel.
 25. The process for forming a plurality of water soluble pouches according to claim 16, wherein said frame and said plurality of integrally formed fluid distributors joined to said frame are integrally formed with one another.
 26. An assembled manifold comprising: a frame; and a plurality of integrally formed fluid distributors joined to said frame; wherein each of said integrally formed fluid distributors comprises a primary flow path; and wherein said primary flow path is in fluid communication with a plurality of secondary flow paths.
 27. The assembled manifold according to claim 26, wherein each of said secondary flow paths is devoid of inactive corners within said secondary flow paths.
 28. The assembled manifold according to claim 27, wherein said frame has a machine direction and cross direction orthogonal to said machine direction, wherein each of said fluid distributors comprises a plurality of said primary flow paths aligned with one another in said machine direction.
 29. The assembled manifold according to claim 28, wherein each of said secondary flow paths aligned with one another in said machine direction are in fluid communication with a separate primary flow path.
 30. The assembled manifold according to claim 28, wherein each of said fluid distributors comprises a plurality of said primary flow paths aligned with one another in said cross direction, wherein each of said primary flow paths are in fluid communication with separate fluid distributors.
 31. The assembled manifold according to claim 28, wherein said assembled manifold comprises a plurality of said primary flow paths aligned with one another in said cross direction.
 32. The assembled manifold according to claim 28, wherein each of said secondary flow paths terminates at a separate nozzle.
 33. The assembled manifold according to claim 26, wherein said primary flow paths and secondary flow paths comprise a material selected from the group consisting of titanium 6-4, cobalt-chrome, and stainless steel.
 34. The assembled manifold according to claim 26, wherein said frame and said plurality of integrally formed fluid distributors joined to said frame are integrally formed with one another.
 35. A process for filling a portion of a water soluble pouch comprising the steps of: providing an assembled manifold of claim 26; and dispensing liquid substrate treatment composition from said assembled manifold into a portion of said water soluble pouch. 